Panasonic U-16GE2E5 Test Run Manual
Gas heat pump air conditioner 2way multi / w multi
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Summary of Contents for Panasonic U-16GE2E5
- Page 1 Gas Heat Pump Air Conditioner Test Run Manual April 2012 Applicable Models 2WAY MULTI/W MULTI U-16GE2E5 U-16GEP2E5 U-20GE2E5 U-20GEP2E5 U-25GE2E5 U-25GEP2E5 U-30GE2E5 Reference No. SM7110029-01...
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Page 2: Table Of Contents
CONTENTS I. Test run operations 1. Applicable models ........................I-1 2. Limitations on refrigerant tubing length ..................I-2 3. Tools and measuring equipment ....................I-6 II. Test Run Work (when Connecting Indoor Unit) SAFETY PRECAUTIONS Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates the remote controller on the indoor unit. -
Page 3: Test Run Operations
I. Test run operations Get the customer to witness the test run. 1. Applicable models Outdoor units Equivalent Model horsepower U-16GE2E5 16 HP U-16GEP2E5 U-20GE2E5 20 HP U-20GEP2E5 U-25GE2E5 25 HP U-25GEP2E5 U-30GE2E5 30 HP Indoor units Class Capacity 2.2/ 2.8/... -
Page 4: Limitations On Refrigerant Tubing Length
2. Limitations on refrigerant tubing length (1) System tubing Limitations on refrigerant tubing length When T-tee branch tubing is used (header branch method) No. 1 branch Symbols 40 cm or less Used for Branch tube expansion (APR purchased separately) 40 cm or less Ball valve (purchased separately) T-tee (provided by installer) Closed (pinch) weld... - Page 5 (2) Selecting system header and branch tubing sizes Outdoor and indoor units are connected together by a pair of headers. If the maximum tubing length exceeds 90 m (effective length), increase the size of the main tubing for both liquid and gas by one size.
- Page 6 Selecting ball valves Valve connection tube diameter (mm) Applicable indoor unit Applicable outdoor Total indoor unit capacity through unit Model Type No. Liquid Balance valve Type 710 φ 31.75 φ 19.05 SGP-BV710K Over 72.8 kW to 101.0 kW (over 90 m) φ...
- Page 7 [Anticipating additional outdoor units] 1) Ball valve installation position: Install on main tubing after branching. 2) Installation guidelines • Slope main tubes after branches so as to prevent oil buildup. • Locate ball valves as close as possible to (within 40 cm) of their branch points. •...
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Page 8: Tools And Measuring Equipment
3. Tools and measuring equipment Item Specifi cation Q’ty Notes Driver ( + ) S, M, L ( - ) M 1 each Monkey wrench 150mm/200mm/250mm 1 each Spanner 1 set Appropriate Leak detection liquid quantity Step ladder Socket wrench 1 set Appropriate For wiping the leak detection... -
Page 9: Test Run Work (When Connecting Indoor Unit)
II. Test Run Work (when Connecting Indoor Unit) Test run fl ow Outdoor unit Indoor unit (1) Checking the construction (5) Checking the indoor units (2) Checking the outdoor unit Remove fi xing pad Checking the gas type External visual check Checking accessory items (3) Safety check Insulation resistance check... -
Page 10: Checking Installation Work (1) Installation Work Check
1. Checking installation work (1) Installation work check If there is a problem with the installation work, make a request through the sales representative that the problem be remedied and measures be taken. Write the necessary information in the “GHP Test Run Checklist (2WAY Multi/W Multi). (Refer to the appendix.) (2) Outdoor unit check Applicable Gas Type Group... -
Page 11: Safety Check
(3) Safety check Insulation resistance check Perform the following procedure to check the insulation up until the unit power terminal block. Turn off the main power supply of the indoor and outdoor units. Turn off the power switch in the terminal box of the outdoor unit. Connect the insulation tester between each of the power terminals of the R phase, O phase, and S phase and the ground terminal on the power terminal block (TB1) in the terminal box, and take measurements. - Page 12 ● Device ground check Is earth ground securely obtained? ● If an error is found in the wiring connections, the following check procedure allows you to quickly identify the location of the error. When performing the check procedure, it is convenient if you have a drawing showing the lay- out of devices and wiring routes to refer to.
- Page 13 II - 5...
- Page 14 Number units to connect Number of units to connect • Maximum possible number of outdoor units ........30 • Maximum possible number of indoor units ........64 • Maximum possible number of centralized control devices ....10 (* Total number of each device within 1 link wire is up to 100.) Wires •...
- Page 15 Remote controller wiring • Wiring : Between remote controller and indoor unit : non polar 2-line format : Between indoor units : non polar 2-line format • Wire thickness : 0.5 mm to 2 mm • Wire length : Total wiring length is max 500m. ( If wireless remote controller exist within group (RCS-BH80BN.WL, SH80BN.WL), wire is up to 400m.) Total wiring between indoor units is up to 200m (ℓ...
- Page 16 Control wire * Indoor/outdoor control wire connection example Bus system (can be branched to max 16 location). Outdoor link is basic. (Figure 5) Outdoor unit Controller Indoor unit Indoor unit Indoor unit Outdoor unit Remote controller At least 2 m Indoor unit Indoor unit Indoor unit...
- Page 17 Wiring without branching (Figure 7) Column: Part of indoor wiring branches. Outdoor unit * If this portion is 1 m or less, it is not considered a branch. Controller Indoor unit Indoor unit Indoor unit Outdoor unit Remote controller Indoor unit Indoor unit Indoor unit No remote...
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Page 18: Indoor Unit Check
Loop wiring is prohibited. (Figure 10) Example: As shown in the fi gure, do not have wiring where part of it is looped or the entire wiring is looped. Outdoor unit Controller Indoor unit Indoor unit Indoor unit Outdoor unit Remote controller Indoor unit Indoor unit... -
Page 19: Preparations And Checks Before Operation
2. Preparations and checks before operation (1) Preparations for operating the outdoor unit Removing the outdoor unit panel • Turn on the breaker to supply power. Crankcase heater 5 hours’ preliminary energization check • Touch the lower part and the bottom surface of the compressor with your hand, and confi rm that it is warm. •... - Page 20 Checking and setting the fuel gas type * When using Propane as the fuel gas it is necessary to adjust the fuel adjustment valve and the gas type setting. <Fuel valve setting> * While the outdoor unit power breaker is OFF, Move the lever of the P/N switch that is attached to the mixer part of the engine to the position shown in the diagram.
- Page 21 The red LED (D052) lights up, indicating a TEST/WARNING. In this condition, use the UP (S005) or DOWN (S006) key to select the gas type. * The relationship between display and gas type is shown in the following table. Display Gas type ...
- Page 22 Checking and adjusting the date and time Checking the date and time a) Select the menu item “ ” to display the current date. Example: (April 1, 2008, in the example) b) With the date displayed, press the SET (S007) key to change to the time display. Example: ...
- Page 23 Checking the initial values Check the initial values of the outdoor unit Press the HOME (S004) key for longer than 1 second, and the menu item number will be displayed. “ ” (If the STOP SW (S001) is on total stop, then after displaying “ ”, “ ” will be displayed) Next, press the UP (S005) or DOWN (S006) key to display menu item number “...
- Page 24 Setting of number of indoor units connected * Set the number of connected outdoor units (W MULTI only) and indoor units on the main board of the outdoor unit. * Both of these setting are set to 1 unit at the time of shipment. <Setting the number of outdoor units>...
- Page 25 The red LED (D052) lights up, indicating a TEST/WARNING. In this condition, press the UP (S005) or DOWN (S006) key to select the connection number. * The indication becomes as shown below. * Setting range • W MULTI: From 1 to 48 units. (However, more than 24 indoor units cannot be connected when only a single outdoor unit is installed.) Indication Meaning...
- Page 26 Setting the system address and whether there is a terminating resistance or not * Set the outdoor system address on the outdoor main board. * At the time of shipment, the system address of the outdoor units is set to “System address 1” and the terminating resistance is set to “SHORT.”...
- Page 27 <How to set the outdoor unit address> Press the HOME (S004) key for longer than 1 second, to display the menu item number . “ ” Next, press the UP (S005) or DOWN (S006) key and the menu item number will be displayed. Select “ ”. After “...
- Page 28 Checking the coolant level Check the coolant level from the inspection opening of the exhaust top side panel. The internal display panel has the cutout shapes shown in the detailed diagram to indicate the “L Level” and “H Level.” Make sure the coolant level is at the “H Level.” If there is not enough coolant, add coolant up until the “H Level.”...
- Page 29 Setting the total stop switch Check that energizing has taken place for 5 hours, and then set S001 (STOP SW) of the outdoor main board from the “STOP” side to “NORM” side. The engine will not start up while the switch is set to “STOP.” The indication on the seven-segment display changes from “...
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Page 30: Setting The Address
3. Setting the address (1) Setting the indoor unit addresses automatically * The method of setting the addresses differs depending on the wiring of the indoor unit control wire and power supply. * The addresses of indoor units can be set automatically from the smallest address unit. The remote controller addresses (group control and individual control) can also be set at the same time. - Page 31 <For the case where the power can be turned on for each refrigerant tubing system> * The address of an indoor unit can be set without operating the outdoor unit. * However, the outdoor unit will operate in the event that power is supplied from another system, so give suffi cient consideration to safety.
- Page 32 * The fi nal digit of the heating automatic address setting display shows the progress of the automatic address setting in turn. : Preparing to start automatic address setting : Waiting for indoor unit automatic address setting preparation ...
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Page 33: Setting The Indoor Unit Addresses Manually
(2) Setting the indoor unit address manually The following is the method for the case where the indoor/outdoor control wire spans several outdoor units, but the power to each system cannot be separately turned on or units operated separately. W MULTI System 1 W MULTI System 2 Out- Out-... - Page 34 <Group setting> Using the temperature setting button change the item code. Change the remote controller from “Item code ” to “Item code ” (group setting). Using the time setting button set “Individual = ” when the indoor unit and remote controller are one to one, and “Main = ...
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Page 35: Checking The Indoor Unit Addresses
(3) Checking the indoor unit addresses All checking process are carried out from a wired remote controller. After checking the addresses, attach an address number label to the indoor and outdoor units. (This is needed for sub- sequent maintenance, so be certain to attach the labels) Remote controller Checking the indoor unit address from the position of the main body of the indoor unit This check is carried out for individual operation (with wired remote controller and indoor unit one to one). - Page 36 <Checking all the indoor unit addresses from an arbitrary wired remote controller> It is possible to check the number and location of indoor units connected to the same refrigerant tubing system (with the same system address). In this method all the indoor units on the system are stopped. Press the time setting button and button simultaneously for longer than 4 seconds.
- Page 37 (4) Changing the indoor unit address (when necessary) • All changing operations are carried out from a wired remote controller. • This operation is carried out when you want to change the indoor unit ad- dress after it has been set automatically. •...
- Page 38 Changing the address of all the indoor units on the system In a system with link wiring, it is possible to change the address of the indoor units on the same refrigerant tubing system from an arbitrary wired remote controller. In this method all the indoor units under the link wiring are stopped.
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Page 39: Flow Diagram For Address Setting
(5) Flow diagram for address setting Yes: If the following addresses are not set on the non-volatile memory (ICB) of the indoor control board it will not be possible to carry out the test run. (these are undetermined data at time of shipment) Indoor unit system (outdoor unit) ad- Item Data at... -
Page 40: Checking The Function (1) Changing The Function Setting
4. Checking the function (1) Changing the function setting • If there is an indoor unit with a gas tube valve kit connected within the system, the function setting of that indoor unit can be changed from the outdoor main board of the outdoor unit connected to the indoor unit. •... -
Page 41: Checking The Function Of The Outdoor Unit
(2) Checking the function of the outdoor unit Checks before starting the engine (* Carry out these checks for all outdoor units of the corresponding refrigerant system.) Has the crankcase heater been energized for 5 hours before starting the test run? Is the bottom part of the compressor warmed up? * If the above conditions have not been fulfi... - Page 42 Checking the rotation speed. There should be no hunting (variations in the rotation speed should be within 60min * However, the set revolution speed varies depending on the air conditioning load, so perform this check after about 15 minutes has elapsed since the test run has been set and when operation has stabilized. Checking for error noise or vibrations (* Carry out these checks for all outdoor units of the corresponding refriger- ant system.) Change the number of indoor units from the minimum to the maximum, and at each number of indoor units...
- Page 43 f) After selecting the number of the indoor unit to be forced to stop, press the SET (S007) key for longer than 1 second. The forced thermostat OFF setting is set for the selected indoor unit. TEST/WARNING indicator (red LED (D052)) lights up. In order to cancel the forced stop, after selecting the number of the indoor unit, press the SET (S007) key for longer than 1 second.
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Page 44: Checking The Indoor Units And Remote Controller
(3) Checking the indoor units and remote controller ● Stop the outdoor unit test run and remove the forced thermostat OFF setting on the indoor units. (turn the Stop switch (STOP SW) to “NORMAL”) ● With each remote controller individually, check that the combination of indoor unit and remote controller unit number display label agree. - Page 45 Checking the operation of the auto-fl ap (This is not available for the perimeter type, built-in type, ceiling embedded type, outdoor air processing unit with direct-expansion coil, and water heat exchanger unit.) ● Press the button and check that the fl ap operates. ●...
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Page 46: Checking Performance
5. Checking performance (1) Checking the basic performance of indoor and outdoor units Operate the system in test run mode continuously for at least 30 minutes, and when the refrigerant system has stabi- lized, from the LED on the board note and record the data for each part. In the case of the W MULTI system, check the data for all outdoor units in the same refrigerant system. - Page 47 Oil error time Set engine rpm 800 to 2200 Engine rpm 800 to 2200 Compressor inlet pressure 0.60 to 0.90 0.30 to 1.10 Compressor outlet pressure 2.30 to 3.20 2.40 to 3.30 Compressor inlet temperature °C 5 to 30 0 to 30...
- Page 48 Gas demand regulation value Gas demand input value ↑ Number of units with thermostat Units Thermostat-on average intake °C temperature Thermostat-on average blow out °C temperature ↓ Thermostat-on average E1 °C temperature Thermostat-on average E2 °C ·...
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Page 49: Completion Of Operations
Checking mode changes For these checks select a mode that is different from the mode in which the performance checks were carried out. Press the HOME (S004) key to display the menu item num- ber. “ ” (Figure 27) Next, press the UP (S005) or DOWN (S006) key to select menu item number “... -
Page 50: Operating Instructions
6. Operating instructions (1) Remote controller switch (operation switch) operation and display < Please explain to the customer the method of using the switch and it’s caution points, and the method of responding when the inspection display is shown.> B type remote controller Method of operation ●... - Page 51 ● Auto fl ap (This is not available for the perimeter type, built-in type, ceiling embedded type, outdoor air processing unit with direct-expansion coil, and water heat exchanger unit.) button · When multiple units are connected, this is used for selecting the unit for adjusting the air direction. (during group control) ·...
- Page 52 Displays ● Operation lamp: Lights up during operation. It blinks when an error occurs or a protective device is activated. ● Automatic cooling/heating, heating, drying, cooling, air blowing: Displays the mode set with the operation selection button. ● Temperature setting: Displays the temperature set by the temperature setting button. ●...
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Page 53: Daily Inspection
(2) Daily inspection < Be sure to explain to the customer the necessity of daily inspection and how to carry it out. > Clean the air fi lter periodically. CAUTION If the air fi lter becomes blocked the operation deteriorates, and the protective device can activate and stop the system. -
Page 54: Self-Diagnosis Function Table (Outdoor Unit
7. Self-diagnosis function table (outdoor unit) System A (activation of engine system operation devices) Outdoor Outdoor unit control unit control Contents Contents board board display display Operation is normal CT trouble (starter current detection failure) Engine oil pressure trouble ... - Page 55 System L (settings trouble) Outdoor Outdoor unit control unit control Contents Contents board board display display Indoor unit capacity not set Mismatch of indoor/outdoor unit types (Non-GHP device present) Outdoor unit capacity not set Multiple master units set for group control Indoor unit type setting failure ...
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Page 56: Reference Document
III. Reference Document 1. How to view of the outdoor main board Example: In the case of the “A-3 Outdoor main board” reference, refer to the area around the frame in the fi gure below. III - 1... -
Page 57: Board Switch And Led Arrangement Diagram
2. Board switch and LED arrangement diagram Name Name Terminating resistance ON/OFF switch (S010) CN075 STOP SW (S001) EEPROM Indoor/outdoor communication monitor (D043) CN037 (white) Fuel gas solenoid valve force close switch (S002) CN049 (red) Compressor outlet/inlet pressure sensors. PS1: Inlet, PS2: outlet SET key (S007) DOWN key (S006) CN029 (blue) - Page 58 GHP test run checklist (2WAY MULTI/W MULTI) Model Name: U- Manufacturing No.: 1)S- 11)S- 21)S- 31)S- 41)S- 2)S- 12)S- 22)S- 32)S- 42)S- 3)S- 13)S- 23)S- 33)S- 43)S- 4)S- 14)S- 24)S- 34)S- 44)S- 5)S- 15)S- 25)S- 35)S- 45)S- 6)S- 16)S- 26)S- 36)S- 46)S- 7)S-...
- Page 59 GHP test run checklist (2WAY MULTI/W MULTI) Function Name: U- Manufacturing No.: 1)S- 11)S- 21)S- 31)S- 41)S- 2)S- 12)S- 22)S- 32)S- 42)S- 3)S- 13)S- 23)S- 33)S- 43)S- 4)S- 14)S- 24)S- 34)S- 44)S- 5)S- 15)S- 25)S- 35)S- 45)S- 6)S- 16)S- 26)S- 36)S- 46)S- 7)S-...